Connector element for use in modular wall construction

ABSTRACT

A wall structure comprising opposed panels supported on spaced apart vertical and horizontal channels mounted on support elements having differently configurated structures. The space between the opposed panels can remain open or be filled with a permanent building material. A variety of wall base constructions are provided, together with detachable frame assemblies for mounting doors and windows in the wall structure.

United States Patent Boice Aug. 12, 1975 CONNECTOR ELEMENT FOR USE IN 1,306,339 6/1919 MODULAR WALL CONSTRUCTION 178415 12/ 1930 2,737,266 3/1956 [75] Inventor: G. Newton Boice, McKeesport, Pa. 3 0 3 794 4/19 3 [73] Assignee: Structural Systems, Inc., McKee-Sport 3,475,044 10/1969 Konstant 52/758 R [22] Filed: Aug. 6, 1973 2 A NO: Primary Examiner-Price Faw, Jr. 1 pp Attorney, Agent, or FirmChristel & Bean Related US. Application Data [62] Division of Ser. No. 214,539, Jan. 3, 1972, Pat. No.

3,800,489 [57] ABSTRACT A wall structurecornprising opposed panels supported [52] US. Cl. 403/405; 52/758 C on Spaced apart vertical and horizontal channels [51] Int. Cl E04b l/40 mounted on Support l t having differently con- [58] held of Search 52/758 758 758 figurated structures. The space between the opposed 52/758 758 758 panels can remain open or be filled with a permanent 603; 403/405 building material. A variety of wall base constructions 337 are provided, together with detachable frame assemblies for mounting doors and windows in the wall [56] References Cited Structure UNITED STATES PATENTS 12/1912 Miller 52/758 A 8 Claims, 82 Drawing Figures PATENTED AUG] 21975 FIG. 4A

PATENTEDAUB 1 2197s 3,899,259

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CONNECTOR ELEMENT FOR USE IN MODULAR WALL CONSTRUCTION CROSS REFERENCE TO A RELATED APPLICATION This application is a division of application Ser. No. 214,539, filed Jan. 3, 1972, now US. Pat. No. 3,800,489 issued Apr. 2, 1974.

BACKGROUND OF THE INVENTION This invention relates generally to the construction art and, more particularly, to certain new and useful prefabricated, modular building constructions.

There presently exists a need for an inexpensive and practical form of construction for residential housing, industrial, commercial and institutional buildings which can be mass produced and prefabricated off the job site and readily installed at the construction site by unskilled labor with maximum efficiency. In an effort to satisfy this need, various prefabricated modular building constructions have been proposed to provide structures which can be readily installed and which are demountable and movable to shift walls, partitions and the like to other positions. While these prior known prefabricated constructions partially satisfy this need, they possess certain disadvantages. Some of these constructions include structural elements and components which span the entire width between walls to interfere with the placement of conduits, piping and the like. Sometimes, these known constructions do not provide adequate sound and heat control and are not capable of withstanding abnormally elevated temperatures, such as accompany a fire. Moreover, their versatility is often limited so that the various components constituting the prefabricated construction can not be readily interchanged or combined to form a variety of arrangements.

SUMMARY OF THE INVENTION A primary object of the present invention is to obviate the above disadvantages by providing an improved modular wall construction, which can be quickly erected at the construction site by unskilled labor and which results in a strong and rigid construction, which is attractive in appearance, extremely versatile, relatively low in costs, and which possesses desirable sound and heat control qualities.

Another object of this invention is to provide a detachable, double wall panel construction defining a substantially uninterrupted space therein which can be left undisturbed for the placement of conduits and the like therein, or which can be filled with concrete or other building material in which case the detachable double wall panel construction serves as a pouring form which can either be removed when the building material has set to leave a permanent wall core remaining or which can remain intact to form with such core a composite permanent wall structure.

Another object of the present invention is to provide the foregoing double wall panel construction with a plurality of novel components having a structural configuration whereby they can be used in pairs in a nested relation or combined with each other to support the double wall panel construction in any orientation as perimeter or partition walls.

Still another object of this invention is to provide the foregoing wall construction with various detachable frame assemblies for mounting doors, windows and the like therein.

A further object of the present invention is to provide the foregoing double wall panel construction with supporting base structures in a variety of forms to enable erection of the former in any desired arrangement.

The foregoing and other objects, advantages and characterizing features of this invention will become clearly apparent from the ensuing detailed description of illustrative embodiments thereof, taken together with the accompanying drawings wherein like reference numerals denote like parts throughout the various views.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a fragmentary, perspective view of a modular, double wall structure, constructed in accordance with the present invention;

FIG. 2 is a perspective view of a pair of spaced channel members of this invention;

FIG. 2A is a perspective view of a spacer plug adapted to be interposed between the channel members of FIG. 2;

FIG. 3 is a front elevational view, on a reduced scale, showing the channel members of this invention arranged in a rectangular pattern;

FIG. 4 is a top plan view of a base channel member used with this invention;

FIG. 4A is a vertical sectional view, illustrating one form of a floor edge member incorporated in this invention;

FIG. 5 is a fragmentary, perspective view illustrating basic structural elements in an assembled relation for supporting the channel members in a spaced relation;

FIG. 6 is a vertical sectional view, on an enlarged scale, showing the structural elements of FIG. 5 in combination with the base channel member of FIG. 4, together with various plug elements;

FIG. 6A is a view similar to FIG. 6 showing the assembly of the latter secured together by an anchor element;

FIG. 7 is a horizontal sectional view, on an enlarged scale, taken about on line 77 of FIG. 5, illustrating connector clips for joining the channel members together;

FIG. Sis a fragmentary, vertical sectional view, showing base clips used in conjunction with this invention;

FIG. 9 is a perspective view of a foundation shoe element of this invention;

FIGS. 10 and 11 are perspective views of inner and outer comer foundation shoe elements used in this invention;

FIG. 12 is a perspective view of a combination of differently configurated foundation shoe elements arranged to form a T intersection;

FIG. 13 is a perspective view of a structural bridging plate incorporated in this invention;

FIGS. 14 and 15 are perspective view of inner and outer comer structural angles used in this invention;

FIGS. 16 and 17 are perspective views of inner and outer structural runner angles used in this invention;

FIG. 18 is a fragmentary, sectional perspective view, on an enlarged scale, taken about on line 18-18 of FIG. 4;

FIGS. 19 and 20 are fragmentary, perspective views, illustrating various stages of the formation of one form of spacer used in conjunction with this invention;

FIG. 21 is a fragmentary, longitudinal sectional view of one form of a spacer assembly of this invention;

FIG. 22 is an exploded view of a fastening assembly of this invention;

FIG. 23 is a longitudinal sectional view, partly in elevation, showing the fastening assembly of this invention securing various structural elements together;

FIG. 24 is a fragmentary, perspective view illustrating a cross brace member assembled with one of the corner structural angles of this invention;

FIG. 25 is a horizontal sectional view illustrating some basic components of this invention for supporting the channel members in a spaced relation;

FIG. 26 is a fragmentary, cross sectional view, partly in elevation, illustrating a tool implement of this invention used for detaching interlocked structural members;

FIG. 27 is a fragmentary, sectional view illustrating a portion of a finished double wall construction incorporating the spaced wall panel members of this invention;

FIG. 28 is a fragmentary, sectional view illustrating a modified wall panel member especially adapted for use as a form in the pouring of a pliant building material; 7

FIG. 29 is a fragmentary, horizontal sectional view, on an enlarged scale, taken about on line 29-29 of FIG. 1, showing a corner construction in accord with this invention;

FIG. 30 is a cross sectional view of a corner trim element used in this invention;

FIG. 31 is a cross sectional view of an inner corner filler block used in conjunction with this invention;

FIG. 32 is a cross sectional view of a backing strip incorporated in this invention;

FIG. 33 is a vertical sectional view, on an enlarged scale, taken about on line 3333 of FIG. 1, showing one form of a wall base construction of this invention;

FIG. 34 is a cross sectional view of one form ofa filler block employed in the wall base construction of FIG. 33, shown assembled with a modified form of base clip;

FIG. 35 is a view similar to FIG. 33, showing spaced panel members supported on the wall base construction thereof;

FIG. 36 is a cross sectional view of one form of a base edging member utilized in the wall base construction of FIG. 35;

FIG. 37 is a cross sectional view of another form of a base edging member optionally used in the wall base construction of FIG. 35;

FIG. 37A is a crosssectional view of still another form of a base edging member incorporating electrical connection means therein;

FIG. 38 is a cross sectional view, partly exploded, of another form of wall base construction;

FIG. 39 is a view similar to FIG. 38 showing the various components in an assembled relation;

FIG. 40 is a fragmentary, vertical sectional view, of still another form of a wall base construction of this invention;

FIG. 41 is a cross sectional view of a modified base clip used in conjunction with the wall base construction of FIG. 40;

FIG. 42 is a cross sectional view of another form of filler block of this invention;

FIG. 43 is a cross sectional view of still another form of filler block of this invention;

FIG. 44 is a view similar to FIG. 40, showing a completed wall base construction;

FIG. 45 is a cross sectional view of an element employed in the wall base construction of FIG. 44;

FIG. 46 is a cross sectional view of a carpet retaining element'used in conjunction with the element of FIG. 45;

FIG. 47 is a cross sectional view of a floor edging member used with the wall base construction of FIG. 44;

FIG. 48 is a vertical sectional view, illustrating still another form of a wall base construction of this invention;

FIG. 49 is a cross sectional view of a modified base clip used in conjunction with the wall base construction of FIG. 48;

FIG. 50 is a vertical sectional view, taken about on line 5050 of FIG. 1, showing one form of a threshold assembly;

FIG. 51 is a vertical sectional view of a wall base construction, showing another form of wall base construction;

FIG. 52 is a vertical sectional view illustrating a modified form of wall base construction and threshold assembly;

FIG. 53 is a partially cut away and sectional perspective view of the double wall construction of this invention; showing a threshold component prior to assembly with the former;

FIG. 54 is a fragmentary, horizontal sectional view of a door assembly used in this invention;

FIG. 55 is a partially cut away and fragmentary, sectional perspective view of a door frame assembly component, showing a portion of the door assembly secured thereto;

I FIG. 56 is a horizontal sectional view, on an enlarged scale, taken about on line 56-56 of FIG. 1;

FIG. 57 is a cross sectional view, of a locking member, used in conjunction with the door frame assembly of this invention;

FIG. 58 is a partially cut away and fragmentary, sectional perspective view of a header assembly forming a part of the door frame assembly;

FIG. 59 is a fragmentary, vertical sectional view, on an enlarged scale, taken about on line 5959 of FIG.

FIG. 60 is a vertical sectional view, illustrating portions of the door frame assembly in a solid wall construction;

FIG. 61 is a vertical sectional view, partly in side elevation, showing the header and side frame of the door frame assembly just prior to assembly;

FIG. 62 is a horizontal sectional view taken about on line 6262 of FIG. 60;

FIG. 63 is a view similar to FIG. 61, showing the threshold and side frame of the door frame assembly just prior to assembly;

FIG. 64 is a fragmentary, perspective view of the double wall construction of this invention, illustrating a cut out section for the placement of a window therein;

FIG. 65 is an expanded view of a window frame assembly including a window unit therefor constructed in accordance with this invention;

FIG. 66 is a fragmentary, perspective sectional view, on an enlarged scale, taken about on lines 66-66 of FIG. 1; 

1. A pair of support elements for mounting angularly related structural members thereon, each support element comprising a web portion and at least one extension forming a continuation of said web and formed integral therewith; a plurality of openings provided in said web portion and said extension; tubular spacer elements rigidly secured to one side of said web portion and said extension and having openings therethrough in registry with certain openings in said web and said extension for receiving fastening means therethrough; a flange formed integral with said web portions and projecting laterally outwardly from said web portion at an angle relative thereto; and said pair of support elements being disposed in a laterally spaced relation; said support elements having opposed faces; said spacer elements mounted on one of said support elements being staggered relative to the spacer elements on the other support element and engageable against the opposed face thereof whereby each spacer element opening is in alignment with laterally aligned openings in said support elements to provide registry of said spacer element openings with any pair of aligned openings in said spaced support elements for receiving fastening means therethrough; said spacer elements maintaining said support elements in a spaced-apart relation.
 2. A pair of support elements according to claim 1 wherein said web portions and said extensions are straight and parallel to each other and the flanges of said support elements extend in opposite directions.
 3. A pair of support elements according to claim 1 wherein each of said web portions, said extensions, and said flanges are bent at angles to form angularly related web portions, extensions and flanges; said flanges of said spaced support elements extending in opposite directions relative to each other.
 4. A pair of support elements according to claim 1 wherein said support element flanges are provided with axial extensions; each of said axial extensions having a notch along the inner edge thereof whereby thE opposed notches form a composite opening in the opposed flanges of said support elements.
 5. A pair of support elements for mounting angularly related structural members thereon, each said support element comprising a web portion and at least one extension forming a continuation of said web and formed integral therewith; a plurality of openings provided in said web portion and said extension; tubular spacer elements rigidly secured to one side of said web portion and said extension and having openings therethrough in registry with certain openings in said web and said extension for receiving fastening means therethrough; a flange formed integral with said web ortion and projecting laterally outwardly from said web portion at an angle relative thereto wherein said flange is provided with a plurality of openings; and tubular spacer elements rigidlyy secured to one side of said flange and having openings therethrough in registry with certain of said flange openings for receiving fastening means therethrough; said pair of support elements being disposed in a nested, spaced relation defining opposed faces; said spacer elements mounted on one of said support element opposed faces engagable against the opposed face of said other support element to maintain said support elements in a spaced-apart relation; said spacer element openings being aligned with openings in said other support element for receiving fastening means therethrough.
 6. A pair of support elements according to claim 5 wherein said web portions are straight and parallel to each other and the flanges of said support elements extend in the same direction in a nested, spaced relation.
 7. A pair of support elements according to claim 5 wherein each of said web portions, said extensions and said flanges are bent at angles to form angularly related web portions, extensions and flanges disposed in a nested, spaced part relation.
 8. A support element for mounting angularly related structural members thereon comprising: a web portion and at least one extension forming a continuation of said web and formed integral therewith; a pluraliity of openings provided in said web portion and said extension; tubular spacer elements rigidly secured to one side of said web portion and said extension and having openings therethrough in registry with certain openings in said web and said extension for receiving fastening means therethrough wherein each of said spacer elements comprises a plurality of tabs formed integral with said support element and bent outwardly therefrom to project generally normal thereto; and a sleeve slip fitted over said projecting tabs. 